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WO2009149845A1 - Foamed polyesters and methods for their production - Google Patents

Foamed polyesters and methods for their production Download PDF

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Publication number
WO2009149845A1
WO2009149845A1 PCT/EP2009/003911 EP2009003911W WO2009149845A1 WO 2009149845 A1 WO2009149845 A1 WO 2009149845A1 EP 2009003911 W EP2009003911 W EP 2009003911W WO 2009149845 A1 WO2009149845 A1 WO 2009149845A1
Authority
WO
WIPO (PCT)
Prior art keywords
polyester
thermoplastic
weight
foam
elastomers
Prior art date
Application number
PCT/EP2009/003911
Other languages
German (de)
French (fr)
Inventor
Heinrich Rüger
Michael Gisler
Linus Villiger
Cédric MÜNGER
Original Assignee
Alcan Technology & Management Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=40941894&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=WO2009149845(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Priority claimed from CH01943/08A external-priority patent/CH700050B1/en
Priority to JP2011512864A priority Critical patent/JP5670321B2/en
Priority to SI200930820T priority patent/SI2288643T1/en
Priority to PL09761408T priority patent/PL2288643T3/en
Priority to BRPI0915376A priority patent/BRPI0915376A2/en
Priority to EP09761408.5A priority patent/EP2288643B1/en
Priority to ES09761408.5T priority patent/ES2439713T3/en
Application filed by Alcan Technology & Management Ltd. filed Critical Alcan Technology & Management Ltd.
Priority to CN200980121758.8A priority patent/CN102056967B/en
Priority to DK09761408.5T priority patent/DK2288643T3/en
Priority to RU2011100164/05A priority patent/RU2482138C2/en
Priority to US12/996,648 priority patent/US20110082227A1/en
Priority to CA2727639A priority patent/CA2727639C/en
Publication of WO2009149845A1 publication Critical patent/WO2009149845A1/en
Priority to HRP20140054AT priority patent/HRP20140054T1/en

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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/04Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
    • C08J9/12Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
    • C08J9/122Hydrogen, oxygen, CO2, nitrogen or noble gases
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/22After-treatment of expandable particles; Forming foamed products
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34Auxiliary operations
    • B29C44/36Feeding the material to be shaped
    • B29C44/46Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length
    • B29C44/50Feeding the material to be shaped into an open space or onto moving surfaces, i.e. to make articles of indefinite length using pressure difference, e.g. by extrusion or by spraying
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0014Use of organic additives
    • C08J9/0023Use of organic additives containing oxygen
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0061Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L67/00Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L67/00Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
    • C08L67/02Polyesters derived from dicarboxylic acids and dihydroxy compounds
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2201/00Foams characterised by the foaming process
    • C08J2201/02Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
    • C08J2201/022Foams characterised by the foaming process characterised by mechanical pre- or post-treatments premixing or pre-blending a part of the components of a foamable composition, e.g. premixing the polyol with the blowing agent, surfactant and catalyst and only adding the isocyanate at the time of foaming
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2201/00Foams characterised by the foaming process
    • C08J2201/02Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
    • C08J2201/03Extrusion of the foamable blend
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2203/00Foams characterized by the expanding agent
    • C08J2203/06CO2, N2 or noble gases
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2205/00Foams characterised by their properties
    • C08J2205/04Foams characterised by their properties characterised by the foam pores
    • C08J2205/052Closed cells, i.e. more than 50% of the pores are closed
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2367/00Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Derivatives of such polymers
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2367/00Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Derivatives of such polymers
    • C08J2367/02Polyesters derived from dicarboxylic acids and dihydroxy compounds
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2400/00Characterised by the use of unspecified polymers
    • C08J2400/14Water soluble or water swellable polymers, e.g. aqueous gels
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2467/00Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Derivatives of such polymers
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/04Oxygen-containing compounds
    • C08K5/09Carboxylic acids; Metal salts thereof; Anhydrides thereof
    • C08K5/092Polycarboxylic acids
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/04Oxygen-containing compounds
    • C08K5/15Heterocyclic compounds having oxygen in the ring
    • C08K5/151Heterocyclic compounds having oxygen in the ring having one oxygen atom in the ring
    • C08K5/1535Five-membered rings
    • C08K5/1539Cyclic anhydrides
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L67/00Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
    • C08L67/02Polyesters derived from dicarboxylic acids and dihydroxy compounds
    • C08L67/025Polyesters derived from dicarboxylic acids and dihydroxy compounds containing polyether sequences

Definitions

  • the invention relates to foam bodies of thermoplastic polyesters, with high homogeneity, low open-cell content and high shear fracture elongation, containing as modifier dianhydrides of tetracarboxylic acids, means for producing the foamed bodies and processes for producing foamed polyesters.
  • thermoplastic polyesters suitable for extrusion foaming have, for example, an intrinsic viscosity of more than 0.8 dl / g.
  • a two-stage process is described, according to which a polyester having an intrinsic viscosity higher than 0.52 dl / g is added with a dianhydride of an organic tetracarboxylic acid and reacted to form a polyester having an intrinsic viscosity of 0.85 to 1.95 dl / g.
  • the foaming process by extrusion foaming can be initiated with the thus prepared polyester.
  • further dianhydride can be added to an organic tetracarboxylic acid during extrusion foaming.
  • foamed polyester can be obtained by forming a molten mixture and extruding this mixture.
  • the mixture is made up of a major portion of polyester and a smaller portion of one Mixture of polyester with a substance formed, the chain extension, resp. Branch, causes.
  • the invention has for its object to propose foams made of polyester, means for their preparation and a process for their preparation in order to foam, resp.
  • Particularly sought-after foams of polyester have, for example, low density, high homogeneity, low open-celledness, high strength and, in particular, high shear fracture elongation.
  • the foaming of polyesters to foam bodies is difficult to control process.
  • intrinsically viscous polyesters (IV) can either not be foamed at all or, if foaming is still possible, the foams have poor properties, such as varying high density, high open-celledness, irregular pore distribution and low shear fracture elongation.
  • the polyester foam of the foam body contains at least one thermoplastic elastomer.
  • foamed bodies of polyesters according to the invention contain thermoplastic elastomers in amounts of from 0.5 to 15.0% by weight, based on the weight of the foam body.
  • thermoplastic elastomers from 0.5 to 12 wt .-%, and preferably from 1, 5 to 12% by weight, each based on the weight of the foam body.
  • the foam bodies of polyesters according to the present invention advantageously comprise as thermoplastic elastomers polymer blends or thermoplastic copolyester elastomers.
  • Thermoplastic elastomers consist of or contain polymers or a polymer blend (blend) which exhibits properties at service temperature. Similar to vulcanized rubber, but which can be processed and worked up at elevated temperatures like a thermoplastic.
  • the polymer blends have a polymer matrix of hard thermoplastic with incorporated particles of soft crosslinked or uncrosslinked elastomers.
  • the thermoplastic copolyester elastomers contain hard thermoplastic sequences and soft elastomeric sequences.
  • thermoplastic copolyester elastomers contain polyester blocks, expediently from a diol, preferably from 1,4-butanediol or 1,2-ethanediol, and a dicarboxylic acid, preferably terephthalic acid, which are reacted with polyesters which carry hydroxyl end groups in a condensation reaction - were restert.
  • Thermoplastic elastomers are also known under the abbreviation TPE and the subgroups TPO (thermoplastic olefin elastomers), TPS (thermoplastic styrene elastomers), TPV (thermoplastic rubber vulcanizates), TPU (thermoplastic urethane elastomers), TPA (thermoplastic polyamide elastomers), TPC (thermoplastic copolyester elastomers) and TPZ (other unclassified thermoplastic elastomers) known.
  • TPE thermoplastic olefin elastomers
  • TPS thermoplastic styrene elastomers
  • TPV thermoplastic rubber vulcanizates
  • TPU thermoplastic urethane elastomers
  • TPA thermoplastic polyamide elastomers
  • TPC thermoplastic copolyester elastomers
  • TPZ other unclassified thermoplastic elastomers
  • the TPEs include block or segmented polymers such as thermoplastic styrenic block polymers, thermoplastic copolyesters, polyetheresters, thermoplastic polyurethanes or polyether-polyamide block copolymers.
  • the TPEs obtain their elastomeric properties either by copolymerizing hard and soft blocks or blending a thermoplastic matrix. In the case of graft copolymerization, the hard segments form so-called domains, which function as physical crosslinks. TPE are repeatedly melted and processed.
  • the TPE described as thermoplastic copolyester elastomers, resp.
  • TPC also called TPC
  • TPC-EE are divided into the TPC-EE with soft segments with ether and ester linkages and the TPC-ES / -ET with soft polyester segments, respectively.
  • Polyether In the present case, the TPC-EE are of particular interest.
  • the thermoplastic copolyester elastomers, resp. thermoplastic copolyester or thermoplastic polyetherester, resp. elastomeric copolyether restoratives are alternately composed of hard polyester segments and soft polyether segments. Depending on the type and length of the hard and soft segments, a wide hardness range is adjustable.
  • Thermoplastic copolyesters are block copolymers consisting on the one hand of amorphous soft segments of polyalkylene ether diols and / or long-chain aliphatic dicarboxylic acid esters and on the other hand of hard segments of crystalline polybutylene terephthalate.
  • the preparation of the elastomeric copolyether esters takes place in the melt by transesterification reactions between a terephthalate ester, a polyalkylene ether glycol (eg polytetramethylene ether glycol, polyethylene oxide glycol or polypropylene oxide glycol) and a short-chain diol, for example 1,4-butanediol or 1,2-ethanediol.
  • a modifier can be added to the polyester.
  • the modifier is, for example, a dianhydride of an organic tetracarboxylic acid (tetracarboxylic acid dianhydride).
  • Preferred dianhydrides are the dianhydrides of the following tetracarboxylic acids:
  • Benzene-1, 2,4,5-tetracarboxylic acid (pyromellitic acid), 3,3 ', 4,4'-diphenyltetracarboxylic acid, 3,3', 4,4'-benzophenonetetracarboxylic acid, 2,2-bis- (3,4-) dicarboxyphenyl) -propane, bis (3,4-dicarboxyphenyl) ether, bis (3,4-dicarboxylphenyl) thioether, naphthalene-2,3,6,7-tetracarboxylic acid, bis (3,4-dicarboxylphenyl) sulfone, tetrahydrofuran-2,3,4,5-tetracarboxylic acid, 2,2-bis (3,4-dicarboxlphenyl) hexafluoropropane, 1, 2,5,6-naphthalenetetracarboxylic acid, bis (3,4-dicarboxyphenyl) - sulfoxide and
  • polyesters such as thermoplastic polyesters obtainable by polycondensation of aromatic dicarboxylic acids with diols.
  • aromatic acids are terephthalic and isophthalic acids, naphthalene dicarboxylic acids and diphenyl ether dicarboxylic acids.
  • diols are glycols such as ethylene glycol, tetraethylene glycol, cyclohexanedimethanol, 1,4-butanediol and 1,2-ethanediol.
  • Polyesters of or containing polyethylene terephthalate, polybutylene terephthalate and polyethylene terephthalate copolymers containing up to 20% of isophthalic acid are preferred.
  • a particularly important feature of the polyesters used as starting material, which are modified according to the invention and foamed to form the foam bodies according to the invention, is the intrinsic viscosity. It has not been possible to produce foams starting from polyesters having an intrinsic viscosity of about 0.4 dl / g. According to the present invention, starting materials, such as of polyesters having an intrinsic viscosity as low as about 0.4 dl / g and above, and especially of polyesters having an intrinsic viscosity of, for example, 0.6 to 0.7 dl / g and above, can reliably form foams be manufactured with the required properties.
  • the proportion of modifier, in particular the tetracarboxylic dianhydride, based on the polyester used, must be increased accordingly.
  • concentration of modifier in the masterbatch and the amount of masterbatch used with respect to the amount of polyester the intrinsic viscosity of the processed polyester, and hence its foamability, is easily controlled.
  • the intrinsic viscosity of 0.6 to 0.7 dl / g can be increased by the modification to above 1, 0 or even 1, 2 dl / g and above.
  • the present invention also relates to compositions for producing foam bodies from polyesters of high homogeneity, low open-cell content and high shear fracture strain, containing as modifier dianhydrides of tetracarboxylic acids.
  • the compositions are a masterbatch containing thermoplastic elastomers, such as copolyester thermoplastic elastomers, in amounts of from 25 to 95% by weight, based on the weight of the composition, and dianhydrides of tetracarboxylic acids in amounts of from 5 to 30% by weight, based on the weight of the agent.
  • compositions for producing foam bodies from polyesters where the composition is a masterbatch comprising thermoplastic copolyester elastomers in amounts of from 25 to 95% by weight and dianhydrides of a tetracarboxylic acid in amounts of from 5 to 30% by weight and 0 to 70%, preferably 1 to 50 wt .-%, each based on the weight of the composition, stabilizers, nucleating agents, flame retardants and / or polyester, suitably a polyester of the same quality, such as a starting polyester to be modified.
  • the means i. the premix can be prefabricated and stored temporarily on a case-by-case basis. Thereafter, in the quantities provided, the premix and the polyesters to be foamed can be mixed together. This mixture of premix and polyesters can be further fed to the foaming process and processed into foam bodies.
  • the present invention also relates to a process for the preparation of foam bodies of polyesters of high homogeneity and shear rate elongation, containing as modifying agent dianhydrides of a tetracarboxylic acid.
  • a polyester resin is admixed with a premix of thermoplastic elastomers, such as thermoplastic copolyester elastomers, and dianhydrides of a tetracarboxylic acid, to give a foam body, containing the ther- moplastic copolyester elastomers in amounts of 0.5 to 15 wt .-%, based on the weight of the foam body, foamed.
  • thermoplastic elastomers such as thermoplastic copolyester elastomers, and dianhydrides of a tetracarboxylic acid
  • thermoplastic elastomers such as thermoplastic co-polyester elastomers and dianhydrides of a tetracarboxylic acid is prepared as a precursor by mixing the ingredients.
  • the masterbatch may contain from 25 to 95% by weight, based on the premix, copolyester elastomers and from 5 to 30% by weight, based on the masterbatch, of tetracarboxylic dianhydride.
  • the premix contains 50 to 90 wt .-%, preferably 80 to 90 wt .-%, based on the masterbatch, copolyester elastomers and 10 to 25 wt%, preferably 10 to 15 wt .-%, based on the premix, tetracarboxylic dianhydride ,
  • the premix may contain as further constituents, for example a total of 0 to 70%, preferably 0.1 to 70% by weight and in particular 1 to 50% by weight, for example polyesters, stabilizers, nucleating agents, fillers and flame retardants.
  • the polyesters listed on the other components may be of the same quality as the polyesters to be modified, i. Starting polyester, e.g. with an intrinsic viscosity above about 0.4 dl / g and in particular polyester having an intrinsic viscosity of about 0.6 to 0.7 dl / g and above, be.
  • the preparation of the premix can be carried out by feeding the components into a mixer, for example a screw extruder, such as a single- or twin-screw extruder or a multi-screw extruder etc., and intimately mixing the components over a period of 10 to 120 seconds at temperatures of 200 to 260 0 C take place.
  • the premix can be discharged from the mixer and be granulated in a further processable form, for example.
  • a polyester with a - Intrinsic viscosity of at least 0.4 dl / g submitted and mixed with the premix.
  • the premix can be used in amounts of 1, 0 to 20.0 wt .-%, based on the polyester.
  • additional components can be added to the mixing and foaming process, in addition to the polyester and the premix.
  • these are the stabilizers, fillers and flame retardants already mentioned, which can be added instead of or not already contained in the premix.
  • the amounts of further components are, for example, up to 15% by weight, advantageously from 0.1 to 15% by weight, based on the sum of polyester and premix.
  • Other components for example for controlling cell size and cell distribution in the foam, can also be added to the mixing and foaming process. These are, for example, up to 5% by weight, suitably from 0.1 to 5% by weight, based on the sum of polyester and premix, of metal compounds of I. to III. Group in the periodic system, e.g. Sodium carbonate, calcium carbonate, aluminum or magnesium stearate, aluminum or magnesium myristate or sodium terephthalate and the other suitable compounds, such. Talc or titanium dioxide.
  • the components can be fed to and mixed in a reactor or mixer, for example a single- or twin-screw extruder or a multi-screw extruder or a tandem unit consisting of two single-screw extruders combined together or combined with one another, a twin-screw extruder and a single-screw extruder.
  • the residence time of the components in the reactor or mixer can be for example from 8 to 40 minutes.
  • the temperature during the residence time can be from 240 to 320 ° C.
  • the blowing agent for foaming is also fed to the reactor or mixer, for example the extruders mentioned.
  • Suitable propellants are, for example, easily vaporizable liquids, thermally decomposing substances that release gases or inert gases and mixtures or combinations mentioned Medium.
  • the readily volatile liquids include saturated aliphatic or cycloaliphatic hydrocarbons, aromatic hydrocarbons and halogenated hydrocarbons. Examples are butane, pentane, hexane, cyclohexane, ethanol, acetone and HFC 152a.
  • As an inert gas CO 2 and nitrogen can be mentioned.
  • the blowing agent is usually fed into the extruder after the feed zone, the components.
  • the foam body of substantially largely closed-cell foam, which may have, for example, a round, rounded, rectangular or polygonal cross-section.
  • the foam body can then be as far as required, according to the use, deformed, cut and / or joined. If foamed bodies are produced, then the foamed bodies can be stacked next to one another and / or one above the other and processed to form foam blocks, in particular homogeneous foam blocks, with mutual release-resistant connection, such as mutual bonding or, in particular, welding.
  • the foam bodies can be plate-shaped and stacked. The touching surfaces can be connected to each other over the entire surface, as if welded. This results in foam blocks with welds that run in the extrusion direction. It can, in particular transversely to the extrusion direction, resp. transverse to the welds, individual foam sheets are separated from the foam block.
  • the foam body according to the invention has, in particular, the following advantageous features at a bulk density of about 120 kg / m 3 :
  • Shear strength according to ISO 1922 for example greater than 1.0 N / mm 2
  • - shear modulus (G-modulus) according to ASTM C393, for example greater than 20 N / mm 2 .
  • Airex method AM-19 Open cell according to Airex method AM-19 according to ASTM D1056-07, for example, of less than 8% and in particular less than 4%.
  • the viscosity number of the resulting foam is determined according to ISO 1628/5 and may for example be more than 150 ml / g, approximately corresponding to an intrinsic viscosity of more than 1.2 dl / g.
  • a viscosity number of the resulting foam, determined according to ISO 1628/5 of, for example, more than 160 ml / g, approximately corresponding to an intrinsic viscosity of more than 1.30 dl / g.
  • the process according to the invention is also distinguished, for example, by the fact that no gel formation takes place during extrusion.
  • the premix is fully miscible with the polyester and no second undesirable phase forms.
  • the premix can be produced in devices known per se, the so-called compounding devices, the process being light is controllable.
  • the properties of the resulting foam body can also be controlled in a simple manner by the choice of the thermoplastic copolyester elastomer (TPC) and the soft elastomers and hard thermoplastic sequences contained therein.
  • Thermoplastic copolyester elastomer (TPC) in the form of granules with a Shore hardness of 55 D is dried for 4 hrs. At 100 0 C by means of hot air.
  • TPC Thermoplastic copolyester elastomer
  • PMDA pyromellitic dianhydride
  • the strands are transferred after cooling in a water bath and drying with an air blower in a granulating device by means of rotating blades in a cylindrical granules.
  • the premix thus obtained is after-dried at 70 ° C. for 3 hours.
  • Premix Example 2 Thermoplastic copolyester elastomer (TPC) in the form of granules having a Shore hardness of 33 D is dried for 4 hours at 100 ° C. by means of hot air. On a co-rotating twin-screw extruder with a diameter of 27 mm and an L / D ratio of 40, 85% by weight of TPC and 15% by weight of pyromellitic dianhydride (PMDA) are used at a cylinder temperature between 200 and 210 ° C. and a speed of 200 rpm mixed under protective gas atmosphere and discharged in strand form.
  • TPC Thermoplastic copolyester elastomer
  • PMDA pyromellitic dianhydride
  • the strands are transferred after cooling in a water bath and drying with an air blower in a granulating device by means of rotating blades in a cylindrical granules.
  • the premix thus obtained is after-dried at 70 ° C. for 3 hours.
  • Polyester granules (PET) with an intrinsic viscosity of 0.81 dl / g are dried for 8 hrs. At 150 0 C by means of hot air.
  • PET PET granules
  • PMDA pyromellitic anhydride
  • the strands are transferred after cooling in a water bath and drying with an air blower in a granulating device by means of rotating blades in a cylindrical granules.
  • the premix thus obtained is after-dried at 70 ° C. for 3 hours.
  • PET granules as starting material having an intrinsic viscosity of 0.81 dl / g are dried for about 5 hours at 170 0 C with dry air and together with 2.7 wt .-% of the premix of Example 1 ( about 11 hours dried with dry air at 60 ° C.) and 1.0% of a nucleating agent (30% talc in PET, dried for about 11 hours with dry air at 60 ° C.) are metered into the first extruder of an extrusion foaming plant with two screw extruders, melted, mixed and foamed with CO 2 .
  • the melt temperature at the exit from the extrusion die is 248 ° C, the output approx.
  • foam bodies for example approximately cuboidal cross-section, which are cut to plate-shaped foam bodies.
  • the plate-shaped foam bodies are stacked and welded to one another at the contact surfaces, forming foam blocks.
  • the measured values given in the examples are determined on foam sheets which are separated from the foam blocks transversely to the extrusion direction.
  • the viscosity number of the resulting foam is determined according to ISO 1628/5 and is 164.0 ml / g, which corresponds to an intrinsic viscosity of 1.32 dl / g.
  • PET granules having an intrinsic viscosity of 0.81 dl / g are dried for about 5 hours at 170 0 C with dry air and together with 2.7 wt .-% of the premix of Example 2 (ca. Dried for 11 hours with dry air at 60 ° C.) and 1.0% of a nucleating agent (30% talc in PET, dried for about 11 hours with dry air at 60 ° C.) are metered into the first extruder of an extrusion foaming plant with two screw extruders, melted. zen, mixed and foamed with CO 2 .
  • the melt temperature at the exit from the extrusion die is 249 ° C.
  • the output is about 290 kg / h
  • the residence time in the extruder is about 17 min.
  • the viscosity number of the resulting foam is determined according to ISO 1628/5 and is 165.6 ml / g, which corresponds to an intrinsic viscosity of 1.33 dl / g.
  • PET granules having an intrinsic viscosity of 0.81 dl / g are dried for about 5 hours at 170 0 C with dry air and together with 2.3 wt .-% of the premix of Example 2 (ca.
  • a nucleating agent (30% talc in PET, dried for about 11 hours with dry air at 60 ° C.) and 10% by weight of a thermoplastic copolyester elastomer (TPC) with a Shore hardness of 33 D (dried for about 12 hours with dry air at 100 ° C.) is metered into the first extruder of an extrusion foaming plant with two screw extruders, melted, mixed and foamed with CO 2 .
  • the melt temperature at the exit from the extrusion die is 248 ° C, the output about 270 kg / h, the residence time in the extruder about 18 min.
  • the viscosity number of the resulting foam is determined according to ISO 1628/5 and amounts to 162.2 ml / g, which corresponds to an intrinsic viscosity of 1.30 dl / g.
  • PET granules having an intrinsic viscosity of 0.81 dl / g are dried for about 5 hours at 170 0 C with dry air and together with 2.7 wt .-% of the premix of the comparative example (ca. 11 hours dried with dry air at 60 ° C.) and 1.0% of a nucleating agent (30% talc in PET, dried for about 11 hours with dry air at 60 ° C.) are metered into the first extruder of an extrusion foaming plant with two screw extruders, melted, mixed and foamed with CO 2 .
  • the melt temperature at the outlet from the extrusion tool is 247 0 C.
  • the emissions must be reduced to about 200 kg / h in order to realize the required Offenzelltechnikswert of ⁇ 8%.
  • the residence time in the extruder thus increases to about 24 minute
  • the viscosity number of the resulting foam according to ISO 1628/5 is lower than in Examples 1 and 2, and thus also the correlating intrinsic viscosity (1.27 dl / g), despite the longer residence time at 157.8 ml / g.

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Abstract

Foams composed of thermoplastic polyesters with high homogeneity, low open-cell factor and high elongation at break under shear stress, where the polyester foam comprises amounts of, for example, from 0.5 to 15% by weight of at least one thermoplastic elastomer, for example a thermoplastic copolyester elastomer, based on the weight of the foam. The foams are obtainable via foaming of a starting polyester of low intrinsic viscosity in a mixture with a modifier in the form of a premix comprising dianhydrides of tetracarboxylic acids and thermoplastic copolyester elastomers.

Description

Geschäumte Polyester und Verfahren zu deren Herstellung Foamed polyesters and process for their preparation
Die Erfindung betrifft Schaumkörper aus thermoplastischen Polyestem, mit hoher Homogenität, niedriger Offenzelligkeit und hoher Schubbruchdehnung, ent- haltend als Modifizierungsmittel Dianhydride von Tetracarbonsäuren, Mittel zur Herstellung der Schaumkörper und Verfahren zur Herstellung von geschäumten Polyestern.The invention relates to foam bodies of thermoplastic polyesters, with high homogeneity, low open-cell content and high shear fracture elongation, containing as modifier dianhydrides of tetracarboxylic acids, means for producing the foamed bodies and processes for producing foamed polyesters.
Es sind beispielsweise aus der WO 93/12164 geschäumte zelluläre Polyester und ein Verfahren zu deren Herstellung bekannt. Es wird beschrieben, dass thermoplastische Polyester, die sich für das Extrusionsschäumen eignen, beispielsweise eine Grenzviskosität (intrinsic viscosity) von mehr als 0,8 dl/g aufweisen. Um den angegebenen Wert der Grenzviskosität zu erhalten, wird ein zweistufiges Verfahren beschrieben, demgemäss ein Polyester mit einer Grenzviskosität von höher als 0,52 dl/g mit einem Dianhydrid einer organischen Tetracarbonsäure versetzt und zur Reaktion gebracht wird, um einen Polyester mit einer Grenzviskosität von 0,85 bis 1.95 dl/g zu erhalten. Mit dem derart aufbereiteten Polyester kann danach der Schäumungsvorgang durch Extrusionsschäumen eingeleitet werden. Fallweise kann während des Extrusionsschäu- mens weiteres Dianhydrid einer organischen Tetracarbonsäure zugegeben werden.For example, WO 93/12164 discloses foamed cellular polyesters and a process for their preparation. It is described that thermoplastic polyesters suitable for extrusion foaming have, for example, an intrinsic viscosity of more than 0.8 dl / g. In order to obtain the specified intrinsic viscosity value, a two-stage process is described, according to which a polyester having an intrinsic viscosity higher than 0.52 dl / g is added with a dianhydride of an organic tetracarboxylic acid and reacted to form a polyester having an intrinsic viscosity of 0.85 to 1.95 dl / g. Thereafter, the foaming process by extrusion foaming can be initiated with the thus prepared polyester. In some cases, further dianhydride can be added to an organic tetracarboxylic acid during extrusion foaming.
Nachteil des genannten Verfahrens ist, dass zwei aufwändige Prozessschritte notwendig sind, um zunächst das ganze Volumen an Polyester mit dem Dian- hydrid der Tetracarbonsäure zu vermischen, und es dann in einem Festphasenreaktor auf Reaktionstemperatur zu bringen und bis zum Ende der Reaktion mehrere Stunden auf Temperatur zu halten. Danach erst schliesst sich der eigentliche Schäumungsvorgang an.The disadvantage of this process is that two complex process steps are necessary in order to first mix the entire volume of polyester with the dianhydride of the tetracarboxylic acid and then bring it to reaction temperature in a solid phase reactor and several hours until the end of the reaction to keep. Only then does the actual foaming process follow.
Gemäss der US 5,288,764 kann geschäumtes Polyester durch Bilden einer geschmolzenen Mischung und Extrudieren dieser Mischung erhalten werden. Die Mischung wird aus einem Hauptanteil Polyester und einem kleineren Teil einer Mischung aus Polyester mit einer Substanz gebildet, die eine Kettenverlängerung, resp. -Verzweigung, bewirkt.According to US 5,288,764, foamed polyester can be obtained by forming a molten mixture and extruding this mixture. The mixture is made up of a major portion of polyester and a smaller portion of one Mixture of polyester with a substance formed, the chain extension, resp. Branch, causes.
Der Erfindung liegt die Aufgabe zugrunde, Schäume aus Polyester, Mittel zu deren Herstellung und ein Verfahren zu deren Herstellung vorzuschlagen, um auf einfache Weise zu Schäumen, resp. Schaumkörpern, aus thermoplastischen Polyestem mit vorteilhaften Eigenschaften zu gelangen. Besonders gesuchte Schäume aus Polyester weisen beispielsweise bei niedriger Dichte, eine hohe Homogenität, eine niedrige Offenzelligkeit, eine hohe Festigkeit und ins- besondere eine hohe Schubbruchdehnung auf. Das Schäumen von Polyestern zu Schaumkörpern ist ein nur schwer beherrsch barer Prozess. Insbesondere Polyester mit niedriger Grenzviskosität (Intrinsic Viscosity, IV), lassen sich entweder gar nicht schäumen oder falls ein Schäumen dennoch möglich ist, so weisen die Schäume schlechte Eigenschaften auf, wie variierende hohe Dichte, hohe Offenzelligkeit, unregelmässige Porenverteilung und geringe Schubbruchdehnung.The invention has for its object to propose foams made of polyester, means for their preparation and a process for their preparation in order to foam, resp. Foam bodies to arrive from thermoplastic polyesters with advantageous properties. Particularly sought-after foams of polyester have, for example, low density, high homogeneity, low open-celledness, high strength and, in particular, high shear fracture elongation. The foaming of polyesters to foam bodies is difficult to control process. In particular, intrinsically viscous polyesters (IV) can either not be foamed at all or, if foaming is still possible, the foams have poor properties, such as varying high density, high open-celledness, irregular pore distribution and low shear fracture elongation.
Zur erfindungsgemässen Lösung der Aufgabe führt, dass der Polyesterschaum des Schaumkörpers wenigstens ein thermoplastisches Elastomer enthält.To solve this problem according to the invention, the polyester foam of the foam body contains at least one thermoplastic elastomer.
Beispielsweise enthalten erfindungsgemässe Schaumkörper aus Polyestern thermoplastische Elastomere in Mengen von 0,5 bis 15,0 Gew.-%, bezogen auf das Gewicht des Schaumkörpers. Zweckmässig sind Mengen an thermoplastischen Elastomeren von 0,5 bis 12 Gew.-%, und bevorzugt von 1 ,5 bis 12 Gew.- %, jeweils bezogen auf das Gewicht des Schaumkörpers.For example, foamed bodies of polyesters according to the invention contain thermoplastic elastomers in amounts of from 0.5 to 15.0% by weight, based on the weight of the foam body. Suitably amounts of thermoplastic elastomers from 0.5 to 12 wt .-%, and preferably from 1, 5 to 12% by weight, each based on the weight of the foam body.
Die Schaumkörper aus Polyestern nach vorliegender Erfindung enthalten als thermoplastische Elastomere vorteilhaft Polymer-Blends oder thermoplastische Copolyesterelastomere.The foam bodies of polyesters according to the present invention advantageously comprise as thermoplastic elastomers polymer blends or thermoplastic copolyester elastomers.
Thermoplastische Elastomere bestehen aus oder enthalten Polymere oder eine Polymermischung (Blend), die bei Gebrauchstemperatur Eigenschaften aufwei- sen, die denen von vulkanisiertem Kautschuk ähnlich sind, die sich jedoch bei erhöhten Temperaturen wie ein thermoplastischer Kunststoff verarbeiten und aufarbeiten lassen. Die Polymer-Blends weisen eine Polymermatrix aus hartem Thermoplast mit darin eingelagerten Partikeln aus weichen vernetzten oder unvernetzten Elastomeren auf. Die thermoplastischen Copolyesterelastomere enthalten harte thermoplastische Sequenzen und weiche elastomere Sequenzen. Die thermoplastischen Copolyesterelastomere enthalten Polyesterblöcke, zweckmässig aus einem Diol, vorzugsweise aus 1 ,4-Butandiol oder 1 ,2-Ethan- diol, und einer Dicarbonsäure, vorzugsweise Terephthalsäure, die mit Polye- thern, die Hydroxyl-Endgruppen tragen, in einer Kondensationsreaktion ve- restert wurden.Thermoplastic elastomers consist of or contain polymers or a polymer blend (blend) which exhibits properties at service temperature. similar to vulcanized rubber, but which can be processed and worked up at elevated temperatures like a thermoplastic. The polymer blends have a polymer matrix of hard thermoplastic with incorporated particles of soft crosslinked or uncrosslinked elastomers. The thermoplastic copolyester elastomers contain hard thermoplastic sequences and soft elastomeric sequences. The thermoplastic copolyester elastomers contain polyester blocks, expediently from a diol, preferably from 1,4-butanediol or 1,2-ethanediol, and a dicarboxylic acid, preferably terephthalic acid, which are reacted with polyesters which carry hydroxyl end groups in a condensation reaction - were restert.
Thermoplastische Elastomere (beispielsweise nach prEN ISO 18064) sind auch unter dem Kürzel TPE und den Untergruppen TPO (thermoplastische Olefine- lastomere), TPS (thermoplastische Styrenelastomere), TPV (thermoplastische Kautschukvulkanisate), TPU (thermoplastische Urethanelastomere), TPA (thermoplastische Polyamidelastomere), TPC (thermoplastische Copolyesterelastomere) und TPZ (sonstige, nicht klassierte thermoplastische Elastomere) bekannt. Zu den TPE gehören Blockpolymere oder Segmentpolymere, wie beispielsweise thermoplastische Styrolblockpolymere, thermoplastische Copoly- ester, Polyetherester, thermoplastische Polyurethane oder Polyether-Polyamid- Blockcopolymere. Die TPE erhalten ihre elastomeren Eigenschaften entweder durch Copolymerisieren von harten und weichen Blöcken oder durch Blenden einer thermoplastischen Matrix. Im Falle von Propfcopolymerisation bilden die Hartsegmente sogenannte Domänen, die als physikalische Vernetzungsstellen fungieren. TPE sind wiederholt aufschmelz- und verarbeitbar. Die TPE, beschrieben als thermoplastische Copolyesterelastomere, resp. auch TPC genannt, sind unterteilt in die TPC-EE mit weichen Segmenten mit Ether- und Esterverknüpfungen und die TPC-ES/-ET mit weichen Polyestersegmenten, resp. Polyethersegmenten. Vorliegend sind die TPC-EE von besonderem Interesse. Die thermoplastischen Copolyesterelastomere, resp. thermoplastischen Copo- lyester oder thermoplastischen Polyetherester, resp. elastomere Copoyethe- rester sind alternierend aus harten Polyestersegmenten und weichen Polyether- segmenten aufgebaut. Je nach Art und Länge der harten und weichen Segmente ist ein breiter Härtebereich einstellbar. Thermoplastische Copolyester sind Blockcopolymere bestehend einerseits aus amorphen Weichsegmenten aus Polyalkylenetherdiolen und/oder langkettigen aliphatischen Dicarbonsäu- reestern und andererseits aus Hartsegmenten aus kristallinem Polybutylente- rephthalat. Die Herstellung der elastomeren Copolyetherester erfolgt in der Schmelze durch Umesterungsreaktionen zwischen einem Terephthalatester, einem Polyalkylenetherglycol (z.B. Polytetramethylenetherglycol, Polyethyleno- xidglycol oder Polypropylenoxidglycol) und einem kurzkettigen Diol, beispielsweise 1 ,4-Butandiol oder 1 ,2-Ethandiol.Thermoplastic elastomers (for example according to prEN ISO 18064) are also known under the abbreviation TPE and the subgroups TPO (thermoplastic olefin elastomers), TPS (thermoplastic styrene elastomers), TPV (thermoplastic rubber vulcanizates), TPU (thermoplastic urethane elastomers), TPA (thermoplastic polyamide elastomers), TPC (thermoplastic copolyester elastomers) and TPZ (other unclassified thermoplastic elastomers) known. The TPEs include block or segmented polymers such as thermoplastic styrenic block polymers, thermoplastic copolyesters, polyetheresters, thermoplastic polyurethanes or polyether-polyamide block copolymers. The TPEs obtain their elastomeric properties either by copolymerizing hard and soft blocks or blending a thermoplastic matrix. In the case of graft copolymerization, the hard segments form so-called domains, which function as physical crosslinks. TPE are repeatedly melted and processed. The TPE, described as thermoplastic copolyester elastomers, resp. also called TPC, are divided into the TPC-EE with soft segments with ether and ester linkages and the TPC-ES / -ET with soft polyester segments, respectively. Polyether. In the present case, the TPC-EE are of particular interest. The thermoplastic copolyester elastomers, resp. thermoplastic copolyester or thermoplastic polyetherester, resp. elastomeric copolyether restoratives are alternately composed of hard polyester segments and soft polyether segments. Depending on the type and length of the hard and soft segments, a wide hardness range is adjustable. Thermoplastic copolyesters are block copolymers consisting on the one hand of amorphous soft segments of polyalkylene ether diols and / or long-chain aliphatic dicarboxylic acid esters and on the other hand of hard segments of crystalline polybutylene terephthalate. The preparation of the elastomeric copolyether esters takes place in the melt by transesterification reactions between a terephthalate ester, a polyalkylene ether glycol (eg polytetramethylene ether glycol, polyethylene oxide glycol or polypropylene oxide glycol) and a short-chain diol, for example 1,4-butanediol or 1,2-ethanediol.
Um bei Polyestem das Molekulargewicht zu erhöhen, kann dem Polyester ein Modifizierungsmittel beigegeben werden. Das Modifizierungsmittel ist beispielsweise ein Dianhydrid einer organischen Tetracarbonsäure (Tetracarbon- säuredianhydrid). Bevorzugte Dianhydride sind die Dianhydride folgender Tetracarbonsäuren:In order to increase the molecular weight of polyesters, a modifier can be added to the polyester. The modifier is, for example, a dianhydride of an organic tetracarboxylic acid (tetracarboxylic acid dianhydride). Preferred dianhydrides are the dianhydrides of the following tetracarboxylic acids:
Benzol-1 ,2,4,5-Tetracarbonsäure (Pyromellitsäure), 3,3',4,4'-Diphenyltetracarbonsäure, 3,3',4,4'-Benzophenontetracarbonsäure, 2,2-Bis-(3,4-dicarboxyphenyl)-propan, Bis-(3,4-dicarboxyphenyl)-ether, Bis-(3,4-dicarboxylphenyl)-thioether, Naphthalin-2,3,6,7-tetracarbonsäure, Bis-(3,4-dicarboxylphenyl)-sulfon, Tetrahydrofuran-2,3,4,5-tetracarbonsäure, 2,2-Bis-(3,4-dicarboxlphenyl) hexafluoropropan, 1 ,2,5,6 -Naphthalintetracarbonsäure, Bis-(3,4-dicarboxyphenyl)-sulfoxid und Mischungen davon. Das bevorzugte Dianhydrid ist das Pyromellitsäuredianhydrid (Benzo!-1 ,2,4,5- tetracarbonsäure-1 ,2:4,5-dianhydrid).Benzene-1, 2,4,5-tetracarboxylic acid (pyromellitic acid), 3,3 ', 4,4'-diphenyltetracarboxylic acid, 3,3', 4,4'-benzophenonetetracarboxylic acid, 2,2-bis- (3,4-) dicarboxyphenyl) -propane, bis (3,4-dicarboxyphenyl) ether, bis (3,4-dicarboxylphenyl) thioether, naphthalene-2,3,6,7-tetracarboxylic acid, bis (3,4-dicarboxylphenyl) sulfone, tetrahydrofuran-2,3,4,5-tetracarboxylic acid, 2,2-bis (3,4-dicarboxlphenyl) hexafluoropropane, 1, 2,5,6-naphthalenetetracarboxylic acid, bis (3,4-dicarboxyphenyl) - sulfoxide and mixtures thereof. The preferred dianhydride is pyromellitic dianhydride (benzo! -1, 2,4,5-tetracarboxylic acid 1, 2: 4,5-dianhydride).
Zur Erzeugung von geschäumten Polyestern anwendbare Ausgangsmaterialien sind Polyester, wie thermoplastische Polyester, die durch Polykondensation von aromatischen Dicarbonsäuren mit Diolen erhältlich sind. Beispiele von aromatischen Säuren sind Terephthal- und Isophthalsäuren, Naphthalindicarbonsäuren und Diphenyletherdicarbonsäuren. Beispiele von Diolen sind Glykole wie Ethy- lenglykol, Tetraethylenglykol, Cyclohexandimethanol, 1 ,4-Butandiol und 1 ,2- Ethandiol.Starting materials which can be used to produce foamed polyesters are polyesters, such as thermoplastic polyesters obtainable by polycondensation of aromatic dicarboxylic acids with diols. Examples of aromatic acids are terephthalic and isophthalic acids, naphthalene dicarboxylic acids and diphenyl ether dicarboxylic acids. Examples of diols are glycols such as ethylene glycol, tetraethylene glycol, cyclohexanedimethanol, 1,4-butanediol and 1,2-ethanediol.
Polyester aus oder enthaltend Polyethylenterephthalat, Polybutylenterephthalat sowie Polyethylenterephthalat-Copolymere enthaltend bis zu 20 % Einheiten Isophthalsäure, sind bevorzugt.Polyesters of or containing polyethylene terephthalate, polybutylene terephthalate and polyethylene terephthalate copolymers containing up to 20% of isophthalic acid are preferred.
Ein besonders wichtiges Merkmal der als Ausgangsmaterial eingesetzten Polyester, die erfindungsgemäss modifiziert und zu den erfindungsgemässen Schaumkörpern geschäumt werden, ist die Grenzviskosität. Es war bis anhin nicht möglich, ausgehend von Polyestern mit einer Grenzviskosität von etwa 0,4 dl/g Schäume herzustellen. Nach vorliegender Erfindung können aus Ausgangsmaterialien, wie aus Polyestern mit einer Grenzviskosität bereits ab Werten von etwa 0,4 dl/g und darüber und insbesondere aus Polyestern mit einer Grenzviskosität von z.B. 0,6 bis 0,7 dl/g und darüber, zuverlässig Schäume mit den geforderten Eigenschaften gefertigt werden. Um tiefe Grenzviskositäten zu erhöhen, muss der Anteil an Modifizierungsmittel, insbesondere des Tetracar- bonsäuredianhydrids, bezogen auf den eingesetzten Polyester, entsprechend erhöht werden. Durch die Wahl der Konzentration des Modifizierungsmittels in der Vormischung und die Menge eingesetzter Vormischung bezüglich der Menge Polyester, lässt sich die Grenzviskosität des verarbeiteten Polyesters - und damit dessen Schäumbarkeit - leicht kontrollieren. Beispielsweise kann die Grenzviskosität von 0,6 bis 0,7 dl/g durch die Modifizierung auf über 1 ,0 oder auch 1 ,2 dl/g und darüber erhöht werden. Vorliegende Erfindung betrifft auch Mittel zur Erzeugung von Schaumkörpern aus Polyestern hoher Homogenität, niedriger Offenzelligkeit und hoher Schubbruchdehnung, enthaltend als Modifizierungsmittel Dianhydride von Tetracarbonsäuren. Die Mittel stellen eine Vormischung dar, enthaltend thermoplastische Elastomere, wie thermoplastische Copolyesterelastomere, in Mengen von 25 bis 95 Gew.-%, bezogen auf das Gewicht des Mittels, und Dianhydride von Tetracarbonsäuren in Mengen von 5 bis 30 Gew.-%, bezogen auf das Gewicht des Mittels.A particularly important feature of the polyesters used as starting material, which are modified according to the invention and foamed to form the foam bodies according to the invention, is the intrinsic viscosity. It has not been possible to produce foams starting from polyesters having an intrinsic viscosity of about 0.4 dl / g. According to the present invention, starting materials, such as of polyesters having an intrinsic viscosity as low as about 0.4 dl / g and above, and especially of polyesters having an intrinsic viscosity of, for example, 0.6 to 0.7 dl / g and above, can reliably form foams be manufactured with the required properties. In order to increase low intrinsic viscosities, the proportion of modifier, in particular the tetracarboxylic dianhydride, based on the polyester used, must be increased accordingly. By choosing the concentration of modifier in the masterbatch and the amount of masterbatch used with respect to the amount of polyester, the intrinsic viscosity of the processed polyester, and hence its foamability, is easily controlled. For example, the intrinsic viscosity of 0.6 to 0.7 dl / g can be increased by the modification to above 1, 0 or even 1, 2 dl / g and above. The present invention also relates to compositions for producing foam bodies from polyesters of high homogeneity, low open-cell content and high shear fracture strain, containing as modifier dianhydrides of tetracarboxylic acids. The compositions are a masterbatch containing thermoplastic elastomers, such as copolyester thermoplastic elastomers, in amounts of from 25 to 95% by weight, based on the weight of the composition, and dianhydrides of tetracarboxylic acids in amounts of from 5 to 30% by weight, based on the weight of the agent.
Bevorzugt sind Mittel zur Erzeugung von Schaumkörper aus Polyestern, wobei das Mittel eine Vormischung darstellt, enthaltend thermoplastische Copolyesterelastomere in Mengen von 25 bis 95 Gew.-% und Dianhydride einer Tetracarbonsäure in Mengen von 5 bis 30 Gew-% sowie 0 bis 70%, vorzugsweise 1 bis 50 Gew.-%, jeweils bezogen auf das Gewicht des Mittels, Stabilisatoren, Nukleierungsmittel, Flammschutzmittel und/oder Polyester, zweckmässig ein Polyester der gleichen Qualität, wie ein zu modifizierender Ausgangspolyester.Preference is given to compositions for producing foam bodies from polyesters, where the composition is a masterbatch comprising thermoplastic copolyester elastomers in amounts of from 25 to 95% by weight and dianhydrides of a tetracarboxylic acid in amounts of from 5 to 30% by weight and 0 to 70%, preferably 1 to 50 wt .-%, each based on the weight of the composition, stabilizers, nucleating agents, flame retardants and / or polyester, suitably a polyester of the same quality, such as a starting polyester to be modified.
Das Mittel, d.h. die Vormischung kann vorgefertigt und fallweise zwischengelagert werden. Danach können, in den vorgesehenen Mengen, die Vormischung und die zu schäumenden Polyester zusammengemischt werden. Diese Mischung aus Vormischung und Polyestern kann weiter dem Schäumprozess zugeführt und zu den Schaumkörpern verarbeitet werden.The means, i. the premix can be prefabricated and stored temporarily on a case-by-case basis. Thereafter, in the quantities provided, the premix and the polyesters to be foamed can be mixed together. This mixture of premix and polyesters can be further fed to the foaming process and processed into foam bodies.
Vorliegende Erfindung betrifft auch ein Verfahren zur Herstellung von Schaumkörpern aus Polyestern hoher Homogenität und Schubbruchdehnung, enthaltend als Modifizierungsmittel Dianhydride einer Tetracarbonsäure.The present invention also relates to a process for the preparation of foam bodies of polyesters of high homogeneity and shear rate elongation, containing as modifying agent dianhydrides of a tetracarboxylic acid.
Nach dem erfindungsgemässen Verfahren zur Herstellung der Schaumkörpern wird ein Polyesterharz mit einer Vormischung aus thermoplastischen Elastomeren, wie thermoplastischen Copolyesterelastomeren, und Dianhydriden einer Tetracarbonsäure versetzt und zu einem Schaumkörper, enthaltend die ther- moplastischen Copolyesterelastomere in Mengen von 0,5 bis 15 Gew.-%, bezogen auf das Gewicht des Schaumkörpers, aufgeschäumt.According to the novel process for producing the foam bodies, a polyester resin is admixed with a premix of thermoplastic elastomers, such as thermoplastic copolyester elastomers, and dianhydrides of a tetracarboxylic acid, to give a foam body, containing the ther- moplastic copolyester elastomers in amounts of 0.5 to 15 wt .-%, based on the weight of the foam body, foamed.
Die Vormischung aus thermoplastische Elastomere, wie thermoplastischen Co- polyesterelastomeren, und Dianhydriden einer Tetracarbonsäure wird als Vorprodukt durch Mischen der Bestandteile hergestellt. Die Vormischung kann 25 bis 95 Gew.-%, bezogen auf die Vormischung, Copolyesterelastomere und 5 bis 30 Gew-%, bezogen auf die Vormischung, Tetracarbonsäuredianhydrid enthalten. Zweckmässig enthält die Vormischung 50 bis 90 Gew.-%, vorteilhaft 80 bis 90 Gew.-%, bezogen auf die Vormischung, Copolyesterelastomere und 10 bis 25 Gew-%, vorteilhaft 10 bis 15 Gew.-%, bezogen auf die Vormischung, Tetracarbonsäuredianhydrid.The premix of thermoplastic elastomers such as thermoplastic co-polyester elastomers and dianhydrides of a tetracarboxylic acid is prepared as a precursor by mixing the ingredients. The masterbatch may contain from 25 to 95% by weight, based on the premix, copolyester elastomers and from 5 to 30% by weight, based on the masterbatch, of tetracarboxylic dianhydride. Suitably, the premix contains 50 to 90 wt .-%, preferably 80 to 90 wt .-%, based on the masterbatch, copolyester elastomers and 10 to 25 wt%, preferably 10 to 15 wt .-%, based on the premix, tetracarboxylic dianhydride ,
Die Vormischung kann als weitere Bestandteile, beispielsweise insgesamt 0 bis 70%, vorzugsweise 0,1 bis 70 Gew.-% und insbesondere 1 bis 50 Gew.-%, beispielsweise Polyester, Stabilisatoren, Nukleierungsmittel, Füllstoffe und Flamm- Schutzmittel enthalten. Die zu den weiteren Bestandteilen angeführten Polyester können von der gleichen Qualität, wie die zu modifizierenden Polyester, d.h. Ausgangspolyester, z.B. mit einer Grenzviskosität ab etwa 0,4 dl/g und insbesondere Polyester mit einer Grenzviskosität von ca. 0,6 bis 0,7 dl/g und darüber, sein.The premix may contain as further constituents, for example a total of 0 to 70%, preferably 0.1 to 70% by weight and in particular 1 to 50% by weight, for example polyesters, stabilizers, nucleating agents, fillers and flame retardants. The polyesters listed on the other components may be of the same quality as the polyesters to be modified, i. Starting polyester, e.g. with an intrinsic viscosity above about 0.4 dl / g and in particular polyester having an intrinsic viscosity of about 0.6 to 0.7 dl / g and above, be.
Die Bereitstellung der Vormischung kann durch Zuführen der Bestanteile in einen Mischer, beispielsweise einen Schneckenextruder, wie einen Ein- oder Doppelschneckenextruder oder einen Mehrwellenextruder etc., und einer innigen Vermischung der Bestandteile über eine Zeitraum von 10 bis 120 Sekun- den bei Temperaturen von 200 bis 2600C erfolgen. Die Vormischung kann aus dem Mischer ausgebracht und in eine weiter verarbeitbare Form, z.B. granuliert, werden.The preparation of the premix can be carried out by feeding the components into a mixer, for example a screw extruder, such as a single- or twin-screw extruder or a multi-screw extruder etc., and intimately mixing the components over a period of 10 to 120 seconds at temperatures of 200 to 260 0 C take place. The premix can be discharged from the mixer and be granulated in a further processable form, for example.
Zur Herstellung der Schaumkörper aus Polyestern erfolgt durch einen Misch- und Schäumprozess. Dazu wird beispielsweise ein Polyester mit einer - Grenzviskosität von wenigstens 0,4 dl/g, vorgelegt und mit der Vormischung versetzt. Die Vormischung kann in Mengen von 1 ,0 bis 20,0 Gew.-%, bezogen auf den Polyester, eingesetzt werden. Vorteilhaft sind Mengen von 2,0 bis 4,0 Gew.-%, bezogen auf den Polyester.To produce the foam body of polyesters is carried out by a mixing and foaming process. For example, a polyester with a - Intrinsic viscosity of at least 0.4 dl / g, submitted and mixed with the premix. The premix can be used in amounts of 1, 0 to 20.0 wt .-%, based on the polyester. Advantageously, amounts of 2.0 to 4.0 wt .-%, based on the polyester.
Fallweise können zusätzlich zum Polyester und der Vormischung weitere Komponenten dem Misch- und Schäumprozess, zugeführt werden. Es sind dies die bereits erwähnten Stabilisatoren, Füllstoffe und Flammschutzmittel, die anstelle oder soweit nicht schon in der Vormischung enthalten, zugeführt werden kön- nen. Die Mengen weiterer Komponenten sind beispielsweise bis zu 15 Gew.-%, zweckmässig 0,1 bis 15 Gew.-%, bezogen auf die Summe von Polyester und Vormischung. Weitere Komponenten, beispielsweise zur Steuerung der ZeII- grösse und der Zellverteilung im Schaum, können ebenfalls dem Misch- und Schäumprozess zugeführt werden. Es sind dies beispielsweise bis zu 5 Gew.- %, zweckmässig 0,1 bis 5 Gew.-%, (bezogen auf die Summe von Polyester und Vormischung) an Metallverbindungen der I. bis III. Gruppe im periodischen System, wie z.B. Natriumcarbonat, Calciumcarbonat, Aluminium- oder Magne- siumstearat, Aluminium- oder Magnesiummyrisat oder Natriumterephtalat und die weiteren geeigneten Verbindungen, wie z.B. Talkum oder Titandioxid.In some cases, additional components can be added to the mixing and foaming process, in addition to the polyester and the premix. These are the stabilizers, fillers and flame retardants already mentioned, which can be added instead of or not already contained in the premix. The amounts of further components are, for example, up to 15% by weight, advantageously from 0.1 to 15% by weight, based on the sum of polyester and premix. Other components, for example for controlling cell size and cell distribution in the foam, can also be added to the mixing and foaming process. These are, for example, up to 5% by weight, suitably from 0.1 to 5% by weight, based on the sum of polyester and premix, of metal compounds of I. to III. Group in the periodic system, e.g. Sodium carbonate, calcium carbonate, aluminum or magnesium stearate, aluminum or magnesium myristate or sodium terephthalate and the other suitable compounds, such. Talc or titanium dioxide.
Die Komponenten können einem Reaktor oder Mischer, beispielsweise einem Ein- oder Doppelschneckenextruder oder einem Mehrwellenextruder oder einer Tandemanlage aus zwei miteinander kombinierten Einschneckenextrudern oder aus, miteinander kombiniert, einem Doppel- und einem Einschneckenextruder zugeführt und vermischt werden. Die Verweilzeit der Komponenten im Reaktor oder Mischer kann beispielsweise von 8 bis 40 Minuten betragen. Die Temperatur während der Verweilzeit kann von 240 bis 3200C betragen.The components can be fed to and mixed in a reactor or mixer, for example a single- or twin-screw extruder or a multi-screw extruder or a tandem unit consisting of two single-screw extruders combined together or combined with one another, a twin-screw extruder and a single-screw extruder. The residence time of the components in the reactor or mixer can be for example from 8 to 40 minutes. The temperature during the residence time can be from 240 to 320 ° C.
Dem Reaktor oder Mischer, z.B. den genannten Extrudern, wird auch das Treib- mittel zum Aufschäumen zugeführt. Geeignete Treibmittel sind beispielsweise leicht verdampfbare Flüssigkeiten, thermisch zersetzende Stoffe, die Gase freisetzen oder Inertgase sowie Mischungen oder Kombinationen genannter Mittel. Zu den leicht verdampfbaren Flüssigkeiten gehören gesättigte aliphati- sche oder cycloaliphatische Kohlenwasserstoffe, aromatische Kohlenwasserstoffe und halogenierte Kohlenwasserstoffe. Beispiele sind Butan, Pentan, Hexan, Cyclohexan, Ethanol, Aceton und HFC 152a. Als inertes Gas kann CO2 und Stickstoff genannt werden. Das Treibmittel wird in der Regel nach dem Zuführungsbereich die Komponenten in den Extruder eingespeist.The blowing agent for foaming is also fed to the reactor or mixer, for example the extruders mentioned. Suitable propellants are, for example, easily vaporizable liquids, thermally decomposing substances that release gases or inert gases and mixtures or combinations mentioned Medium. The readily volatile liquids include saturated aliphatic or cycloaliphatic hydrocarbons, aromatic hydrocarbons and halogenated hydrocarbons. Examples are butane, pentane, hexane, cyclohexane, ethanol, acetone and HFC 152a. As an inert gas CO 2 and nitrogen can be mentioned. The blowing agent is usually fed into the extruder after the feed zone, the components.
An der formgebenden Auslassöffnung des Extruders entsteht kontinuierlich der Schaumkörper aus im wesentlichen weitestgehend geschlossenzelligem Schaum, der beispielsweise einen runden, gerundeten, rechteckigen oder polygonalen Querschnitt aufweisen kann. Der Schaumkörper kann danach soweit gefordert, nach Massgabe des Einsatzes, verformt, geschnitten und/oder gefügt werden. Werden Schaumkörper erzeugt, so können die Schaumkörper nebeneinander und/oder übereinander gestapelt werden und unter gegenseiti- ger trennfester Verbindung, wie gegenseitiges verkleben oder insbesondere verschweissen, zu Schaumstoffblöcken, insbesondere homogenen Schaumstoffblöcken, verarbeitet werden. Die Schaumkörper können plattenförmig sein und gestapelt werden. Die sich berührenden Flächen können vollflächig miteinander verbunden, wie verschweisst, werden. Dadurch entstehen Schaumstoff- blocke mit Schweissnähten, die in Extrusionsrichtung laufen. Es können, insbesondere quer zur Extrusionsrichtung, resp. quer zu den Schweissnähten, vom Schaumstoffblock einzelne Schaumstoffplatten abgetrennt werden.At the forming outlet opening of the extruder is continuously formed the foam body of substantially largely closed-cell foam, which may have, for example, a round, rounded, rectangular or polygonal cross-section. The foam body can then be as far as required, according to the use, deformed, cut and / or joined. If foamed bodies are produced, then the foamed bodies can be stacked next to one another and / or one above the other and processed to form foam blocks, in particular homogeneous foam blocks, with mutual release-resistant connection, such as mutual bonding or, in particular, welding. The foam bodies can be plate-shaped and stacked. The touching surfaces can be connected to each other over the entire surface, as if welded. This results in foam blocks with welds that run in the extrusion direction. It can, in particular transversely to the extrusion direction, resp. transverse to the welds, individual foam sheets are separated from the foam block.
Der erfindungsgemässe Schaumkörper weist insbesondere folgende vorteil- haften Merkmale auf:The foamed body according to the invention has in particular the following advantageous features:
- Sortenreinheit, es sind nur Polyester und keine weiteren artfremden Polymere vorhanden.- Sort purity, there are only polyester and no other dissimilar polymers.
- Regelmässige geschlossenzellige Poren.- Regular closed-cell pores.
Der erfindungsgemässe Schaumkörper weist bei einer Rohdichte von etwa 120 kg/m3 insbesondere folgende vorteilhaften Merkmale auf:The foam body according to the invention has, in particular, the following advantageous features at a bulk density of about 120 kg / m 3 :
- Schubfestigkeit nach ISO 1922 , beispielsweise von grösser als 1.0 N/mm2, - Schubmodul (G-Modul) nach ASTM C393, beispielsweise von grösser als 20 N/mm2.Shear strength according to ISO 1922, for example greater than 1.0 N / mm 2 , - shear modulus (G-modulus) according to ASTM C393, for example greater than 20 N / mm 2 .
- Schubbruchdehnung nach ISO 1922 , beispielsweise mit Werten von mehr als 12 %, zweckmässig von mehr als 16 % und bevorzugt von mehr als 50 %. - Druckfestigkeit nach ISO 844 beispielsweise von grösser als 1.7 N/mm2 - Shear elongation at break according to ISO 1922, for example with values of more than 12%, suitably more than 16% and preferably more than 50%. - Compressive strength according to ISO 844, for example greater than 1.7 N / mm 2
- Druckmodul (E-Modul) nach DIN 53421 , beispielsweise von grösser als 90 N/mm2.- Pressure module (modulus of elasticity) according to DIN 53421, for example of greater than 90 N / mm 2 .
- Offenzelligkeit nach Airex-Methode AM-19 in Anlehnung an ASTM D1056 - 07 beispielsweise von kleiner als 8% und insbesondere kleiner als 4%. Die Offen- zelligkeitsmessung gemäss der Airex-Methode AM-19 wird wie in ASTM D 1056 beschrieben durchgeführt, jedoch mit einer anderen Formel berechnet: ASTM D 1059: W = [(A-B)/B] x 100 mit W = change in mass [%]; A = final mass of specimen; und B = initial mass of specimen. Airex AM-19: OZ = [(A-B)/(LxBxD)] x 100 mit OZ = Offenzelligkeit [Vol-%] A = Gewicht der Probe nach Konditionierung [g]; B = Gewicht der Probe vor Konditionierung [g]; L, B, D = Länge, Breite, Dicke der Probe [cm]; die Dichte des Wassers mit 1 g/cm3 ist in der Formel nicht explizit ausgewiesen. Nach vorliegender Erfindung werden beispielsweise Werte im Wasser-Adsorptions-Test (water adsorption test) von unter 40 Gew.-%, zweckmässig von unter 35 Gew.- % und insbesondere von unter 30 Gew.-% erreicht.- Open cell according to Airex method AM-19 according to ASTM D1056-07, for example, of less than 8% and in particular less than 4%. The open-cell measurement according to the Airex method AM-19 is carried out as described in ASTM D 1056, but calculated using a different formula: ASTM D 1059: W = [(AB) / B] × 100 with W = change in mass %]; A = final mass of specimen; and B = initial mass of specimen. Airex AM-19: OZ = [(AB) / (LxBxD)] x 100 where OZ = open cell [vol%] A = weight of sample after conditioning [g]; B = weight of the sample before conditioning [g]; L, B, D = length, width, thickness of sample [cm]; the density of water at 1 g / cm 3 is not explicitly indicated in the formula. According to the present invention, for example, values in the water adsorption test of less than 40% by weight, expediently less than 35% by weight and in particular less than 30% by weight are achieved.
- Die Viskositätszahl des resultierenden Schaums wird nach ISO 1628/5 bestimmt und kann beispielsweise mehr als 150 ml/g, etwa entsprechend einer Grenzviskosität von mehr als 1 ,2 dl/g, betragen. Bevorzugt ist eine Viskositätszahl des resultierenden Schaums, bestimmt nach ISO 1628/5, von beispiels- weise mehr als 160 ml/g, etwa entsprechend einer Grenzviskosität von mehr als 1 ,30 dl/g.The viscosity number of the resulting foam is determined according to ISO 1628/5 and may for example be more than 150 ml / g, approximately corresponding to an intrinsic viscosity of more than 1.2 dl / g. Preferably, a viscosity number of the resulting foam, determined according to ISO 1628/5, of, for example, more than 160 ml / g, approximately corresponding to an intrinsic viscosity of more than 1.30 dl / g.
Das Verfahren nach der Erfindung zeichnet sich beispielsweise auch dadurch aus, dass beim Extrudieren keine Gel-Bildung stattfindet. Die Vormischung ist vollständig mit dem Polyester mischbar und es bildet sich keine zweite unerwünschte Phase. Die Vormischung lässt sich in an sich bekannten Vorrichtungen, den sog. Compoundiervorrichtungen, herstellen, wobei der Prozess leicht beherrschbar ist. Die Eigenschaften des entstehenden Schaumkörpers lassen sich auch durch die Wahl des thermoplastischen Copolyesterelastomeren (TPC) und der darin enthaltenen weichen Elastomeren und harten thermoplastischen Sequenzen auf einfache Weise steuern.The process according to the invention is also distinguished, for example, by the fact that no gel formation takes place during extrusion. The premix is fully miscible with the polyester and no second undesirable phase forms. The premix can be produced in devices known per se, the so-called compounding devices, the process being light is controllable. The properties of the resulting foam body can also be controlled in a simple manner by the choice of the thermoplastic copolyester elastomer (TPC) and the soft elastomers and hard thermoplastic sequences contained therein.
Beispiele:Examples:
Vormischung Beispiel 1 :Premix Example 1:
Thermoplastisches Copolyesterelastomer (TPC) in Form von Granulat mit einer Shorehärte von 55 D wird während 4 Std. bei 100 0C mittels heisser Luft getrocknet. Auf einem gleichdrehenden Doppelschneckenextruder mit 27 mm- Zylinderdurchmesser und einem L/D-Verhältnis von 40 werden 85 Gew.-% TPC und 15 Gew.-% Pyromellitsäuredianhydrid (PMDA) bei einer Zylindertemperatur zwischen 200 und 210 0C und einer Drehzahl von 200 UpM unter Schutzgas- atmosphäre gemischt und in Strangform ausgetragen. Die Stränge werden nach Abkühlung im Wasserbad und Trocknung mit einem Luftgebläse in einer Granuliervorrichtung mittels rotierender Messer in ein zylindrisches Granulat überführt. Die so erhaltene Vormischung wird während 3 Stunden bei 70 0C nachgetrocknet.Thermoplastic copolyester elastomer (TPC) in the form of granules with a Shore hardness of 55 D is dried for 4 hrs. At 100 0 C by means of hot air. On a co-rotating twin-screw extruder with 27 mm cylinder diameter and an L / D ratio of 40, 85 wt .-% TPC and 15 wt .-% pyromellitic dianhydride (PMDA) at a cylinder temperature between 200 and 210 0 C and a speed of 200 rpm mixed under protective gas atmosphere and discharged in strand form. The strands are transferred after cooling in a water bath and drying with an air blower in a granulating device by means of rotating blades in a cylindrical granules. The premix thus obtained is after-dried at 70 ° C. for 3 hours.
Vormischung Beispiel 2: Thermoplastisches Copolyesterelastomer (TPC) in Form von Granulat mit einer Shorehärte von 33 D wird während 4 Std. bei 100 0C mittels heisser Luft getrocknet. Auf einem gleichdrehenden Doppelschneckenextruder mit 27 mm-Zy- linderdurchmesser und einem L/D-Verhältnis von 40 werden 85 Gew.-% TPC und 15 Gew.-% Pyromellitsäuredianhydrid (PMDA) bei einer Zylindertemperatur zwischen 200 und 210 0C und einer Drehzahl von 200 UpM unter Schutzgasatmosphäre gemischt und in Strangform ausgetragen. Die Stränge werden nach Abkühlung im Wasserbad und Trocknung mit einem Luftgebläse in einem Granuliervorrichtung mittels rotierender Messer in ein zylindrisches Granulat überführt. Die so erhaltene Vormischung wird während 3 Stunden bei 70 0C nachgetrocknet. Vormischung Vergleichsbeispiel:Premix Example 2: Thermoplastic copolyester elastomer (TPC) in the form of granules having a Shore hardness of 33 D is dried for 4 hours at 100 ° C. by means of hot air. On a co-rotating twin-screw extruder with a diameter of 27 mm and an L / D ratio of 40, 85% by weight of TPC and 15% by weight of pyromellitic dianhydride (PMDA) are used at a cylinder temperature between 200 and 210 ° C. and a speed of 200 rpm mixed under protective gas atmosphere and discharged in strand form. The strands are transferred after cooling in a water bath and drying with an air blower in a granulating device by means of rotating blades in a cylindrical granules. The premix thus obtained is after-dried at 70 ° C. for 3 hours. Premix comparative example:
Polyestergranulat (PET)mit einer Grenzviskosität von 0,81 dl/g wird während 8 Std. bei 150 0C mittels heisser Luft getrocknet. Auf der gleichen Anlage wie in Beispiel 1 werden 85 Gew.-% PET-Granulat und 15 Gew.-% Pyromellitsäuredi- anhydrid (PMDA) bei einer Zylindertemperatur zwischen 240 und 250 0C und einer Drehzahl von 200 UpM unter Schutzgasatmosphäre gemischt und in Strangform ausgetragen. Die Stränge werden nach Abkühlung im Wasserbad und Trocknung mit einem Luftgebläse in einem Granuliervorrichtung mittels rotierender Messer in ein zylindrisches Granulat überführt. Die so erhaltene Vormischung wird während 3 Stunden bei 70 0C nachgetrocknet.Polyester granules (PET) with an intrinsic viscosity of 0.81 dl / g are dried for 8 hrs. At 150 0 C by means of hot air. On the same system as in Example 1 85 wt .-% PET granules and 15 wt .-% pyromellitic anhydride (PMDA) at a cylinder temperature between 240 and 250 0 C and a speed of 200 rpm under a protective gas atmosphere mixed and in strand form discharged. The strands are transferred after cooling in a water bath and drying with an air blower in a granulating device by means of rotating blades in a cylindrical granules. The premix thus obtained is after-dried at 70 ° C. for 3 hours.
Tabelle 1Table 1
Versuchsparameter zur Herstellung der VormischungenExperimental parameters for the preparation of premixes
Beispiel Beispiel Vergleichs¬Example Example Vergleich¬
Vormischung 1 2 beispielPremix 1 2 example
Rezepturrecipe
TPC-Anteil Gew-% 85.0 85.0TPC content wt% 85.0 85.0
PET-Anteil Gew-% 85.0PET share wt% 85.0
PMDA-Anteil Gew-% 15.0 15.0 15.0PMDA share weight% 15.0 15.0 15.0
Maschinenparametermachine parameters
Temperatur Einzugszone 0C 200 200 250Temperature feed zone 0 C 200 200 250
Temperatur Mischzone 0C 210 210 250Temperature mixing zone 0 C 210 210 250
Temperatur Austra- 0C 205 205 240 gszoneTemperature Austra- 0C 205 205 240 gszone
Masse-Temperatur 0C 199 204 238Mass temperature 0 C 199 204 238
Masse-Druck bar 34 12 12Mass pressure bar 34 12 12
Ankerstrom Extruder % 52 33 43Anchor flow extruder% 52 33 43
Durchsatz kg/h 20 20 20 Drehzahl Extruder UpM 200 200 200Throughput kg / h 20 20 20 Speed extruder rpm 200 200 200
Abzugsgeschwindigk. m/min 30 30 30Abzugsgeschwindigk. m / min 30 30 30
Vormischungpremix
Schüttdichte g/dl 65.4 59.7 76.5Bulk density g / dl 65.4 59.7 76.5
Schäumung Beispiel 1Foaming Example 1
96,3 Gew.-% PET-Granulat als Ausgangsmaterial mit einer Grenzviskosität von 0,81 dl/g werden ca. 5 Stunden bei 170 0C mit Trockenluft getrocknet und zusammen mit 2,7 Gew.-% der Vormischung aus Beispiel 1 (ca. 11 Stunden getrocknet mit Trockenluft bei 600C) und 1 ,0 % eines Nukleierungsmittels (30 % Talkum in PET; ca. 11 Stunden getrocknet mit Trockenluft bei 600C) werden in den ersten Extruder einer Extrusionsschäumanlage mit zwei Schneckenextrudern dosiert, aufgeschmolzen, vermischt und mit CO2 verschäumt. Die Schmelzetemperatur am Austritt aus dem Extrusionswerkzeug beträgt 248°C, der Aus- stoss ca. 290 kg/h, die Verweilzeit im Extruder ca. 17 min. Es entstehen kontinuierlich Schaumkörper beispielsweise etwa quaderförmigen Querschnitts, die zu plattenförmigen Schaumkörpern abgelängt werden. Die plattenförmigen Schaumkörper werden gestapelt und an den Berührungsflächen gegenseitig verschweisst, wobei Schaumblöcke entstehen. Die in den Beispielen angegebenen Messwerte werden an Schaumplatten, die quer zur Extrusionsrichtung von den Schaumblöcken abgetrennt werden, ermittelt. Die Viskositätszahl des resultierenden Schaums wird nach ISO 1628/5 bestimmt und beträgt 164.0 ml/g, was einer Grenzviskosität von 1 ,32 dl/g entspricht.96.3 wt .-% PET granules as starting material having an intrinsic viscosity of 0.81 dl / g are dried for about 5 hours at 170 0 C with dry air and together with 2.7 wt .-% of the premix of Example 1 ( about 11 hours dried with dry air at 60 ° C.) and 1.0% of a nucleating agent (30% talc in PET, dried for about 11 hours with dry air at 60 ° C.) are metered into the first extruder of an extrusion foaming plant with two screw extruders, melted, mixed and foamed with CO 2 . The melt temperature at the exit from the extrusion die is 248 ° C, the output approx. 290 kg / h, the residence time in the extruder approx. 17 min. There are continuously foam bodies, for example approximately cuboidal cross-section, which are cut to plate-shaped foam bodies. The plate-shaped foam bodies are stacked and welded to one another at the contact surfaces, forming foam blocks. The measured values given in the examples are determined on foam sheets which are separated from the foam blocks transversely to the extrusion direction. The viscosity number of the resulting foam is determined according to ISO 1628/5 and is 164.0 ml / g, which corresponds to an intrinsic viscosity of 1.32 dl / g.
Schäumung Beispiel 2Foaming Example 2
96,3 Gew.-% PET-Granulat mit einer Grenzviskosität von 0,81 dl/g werden ca. 5 Stunden bei 170 0C mit Trockenluft getrocknet und zusammen mit 2,7 Gew.-% der Vormischung aus Beispiel 2 (ca. 11 Stunden getrocknet mit Trockenluft bei 600C) und 1.0 % eines Nukleierungsmittels (30 % Talkum in PET; ca. 11 Stunden getrocknet mit Trockenluft bei 600C) werden in den ersten Extruder einer Extrusionsschäumanlage mit zwei Schneckenextrudern dosiert, aufgeschmol- zen, vermischt und mit CO2 verschäumt. Die Schmelzetemperatur am Austritt aus dem Extrusionswerkzeug beträgt 2490C, der Ausstoss ca. 290 kg/h, die Verweilzeit im Extruder ca. 17 min. Die Viskositätszahl des resultierenden Schaums wird nach ISO 1628/5 bestimmt und beträgt 165,6 ml/g, was einer Grenzviskosität von 1 ,33 dl/g entspricht.96.3 wt .-% PET granules having an intrinsic viscosity of 0.81 dl / g are dried for about 5 hours at 170 0 C with dry air and together with 2.7 wt .-% of the premix of Example 2 (ca. Dried for 11 hours with dry air at 60 ° C.) and 1.0% of a nucleating agent (30% talc in PET, dried for about 11 hours with dry air at 60 ° C.) are metered into the first extruder of an extrusion foaming plant with two screw extruders, melted. zen, mixed and foamed with CO 2 . The melt temperature at the exit from the extrusion die is 249 ° C., the output is about 290 kg / h, the residence time in the extruder is about 17 min. The viscosity number of the resulting foam is determined according to ISO 1628/5 and is 165.6 ml / g, which corresponds to an intrinsic viscosity of 1.33 dl / g.
Schäumung Beispiel 3Foaming Example 3
86,7 Gew.-% PET-Granulat mit einer Grenzviskosität von 0,81 dl/g werden ca. 5 Stunden bei 170 0C mit Trockenluft getrocknet und zusammen mit 2,3 Gew.-% der Vormischung aus Beispiel 2 (ca. 11 Stunden getrocknet mit Trockenluft bei 600C), 1 ,0 % eines Nukleierungsmittels (30 % Talkum in PET; ca. 11 Stunden getrocknet mit Trockenluft bei 600C) und 10 Gew.-% eines thermoplastischen Copolyesterelastomers (TPC) mit einer Shorehärte von 33 D (ca. 12 Stunden getrocknet mit Trockenluft bei 1000C) werden in den ersten Extruder einer Extrusionsschäumanlage mit zwei Schneckenextrudern dosiert, aufgeschmolzen, vermischt und mit CO2 verschäumt. Die Schmelzetemperatur am Austritt aus dem Extrusionswerkzeug beträgt 248°C, der Ausstoss ca. 270 kg/h, die Verweilzeit im Extruder ca. 18 min. Die Viskositätszahl des resultierenden Schaums werden nach ISO 1628/5 bestimmt und betragen 162,2 ml/g, was einer Grenzviskosität von 1 ,30 dl/g entspricht.86.7 wt .-% PET granules having an intrinsic viscosity of 0.81 dl / g are dried for about 5 hours at 170 0 C with dry air and together with 2.3 wt .-% of the premix of Example 2 (ca. Dried for 10 hours with dry air at 60 ° C.), 1.0% of a nucleating agent (30% talc in PET, dried for about 11 hours with dry air at 60 ° C.) and 10% by weight of a thermoplastic copolyester elastomer (TPC) with a Shore hardness of 33 D (dried for about 12 hours with dry air at 100 ° C.) is metered into the first extruder of an extrusion foaming plant with two screw extruders, melted, mixed and foamed with CO 2 . The melt temperature at the exit from the extrusion die is 248 ° C, the output about 270 kg / h, the residence time in the extruder about 18 min. The viscosity number of the resulting foam is determined according to ISO 1628/5 and amounts to 162.2 ml / g, which corresponds to an intrinsic viscosity of 1.30 dl / g.
Schäumung VergleichsbeispielFoaming Comparative Example
96,3 Gew.-% PET-Granulat mit einer Grenzviskosität von 0,81 dl/g werden ca. 5 Stunden bei 170 0C mit Trockenluft getrocknet und zusammen mit 2,7 Gew.-% der Vormischung aus dem Vergleichsbeispiel (ca. 11 Stunden getrocknet mit Trockenluft bei 600C) und 1 ,0 % eines Nukleierungsmittels (30 % Talkum in PET; ca. 11 Stunden getrocknet mit Trockenluft bei 600C) werden in den ersten Extruder einer Extrusionsschäumanlage mit zwei Schneckenextrudem dosiert, aufgeschmolzen, vermischt und mit CO2 verschäumt. Die Schmelzetemperatur am Austritt aus dem Extrusionswerkzeug beträgt 2470C. Der Ausstoss muss auf ca. 200 kg/h reduziert werden, um den geforderten Offenzelligkeitswert von < 8 % zu realisieren. Die Verweilzeit im Extruder erhöht sich dadurch auf ca. 24 min. Die Viskositätszahl des resultierenden Schaumes nach ISO 1628/5 ist trotz der längeren Verweilzeit mit 157,8 ml/g tiefer als in den Beispielen 1 und 2 und damit auch die korrelierende Grenzviskosität (1 ,27 dl/g).96.3 wt .-% PET granules having an intrinsic viscosity of 0.81 dl / g are dried for about 5 hours at 170 0 C with dry air and together with 2.7 wt .-% of the premix of the comparative example (ca. 11 hours dried with dry air at 60 ° C.) and 1.0% of a nucleating agent (30% talc in PET, dried for about 11 hours with dry air at 60 ° C.) are metered into the first extruder of an extrusion foaming plant with two screw extruders, melted, mixed and foamed with CO 2 . The melt temperature at the outlet from the extrusion tool is 247 0 C. The emissions must be reduced to about 200 kg / h in order to realize the required Offenzelligkeitswert of <8%. The residence time in the extruder thus increases to about 24 minute The viscosity number of the resulting foam according to ISO 1628/5 is lower than in Examples 1 and 2, and thus also the correlating intrinsic viscosity (1.27 dl / g), despite the longer residence time at 157.8 ml / g.
Die mechanischen Eigenschaften der erhaltenen Schäume sind in Tabelle 2 aufgeführt.The mechanical properties of the resulting foams are listed in Table 2.
Tabelle 2Table 2
Mechanische Eigenschaften der erhaltenen SchäumeMechanical properties of the foams obtained
Figure imgf000016_0001
Figure imgf000016_0001

Claims

Patentansprüche claims
1. Schaumkörper aus thermoplastischen Polyestem, mit hoher Homogenität, niedriger Offenzelligkeit und hoher Schubbruchdehnung, enthaltend als Modifizierungsmittel Dianhydride von Tetracarbonsäuren,1. Thermoplastic polyester foams of high homogeneity, low open-cell content and high shear fracture strain, containing as modifying agent dianhydrides of tetracarboxylic acids,
dadurch gekennzeichnet, dasscharacterized in that
der Polyesterschaum thermoplastische Elastomere enthält.the polyester foam contains thermoplastic elastomers.
2. Schaumkörper aus Polyestem nach Anspruch 1 , dadurch gekennzeichnet, dass die thermoplastischen Elastomere in Mengen von 0,5 bis 15 Gew.-%, bezogen auf das Gewicht des Schaumkörpers, enthalten sind.2. Foam body of polyester according to claim 1, characterized in that the thermoplastic elastomers in amounts of 0.5 to 15 wt .-%, based on the weight of the foam body, are included.
3. Schaumkörper aus Polyestem nach wenigstens einem der Ansprüche 1 oder 2, dadurch gekennzeichnet, dass als thermoplastische Elastomere im Polyesterschaum thermoplastische Copolyesterelastomere enthalten sind.3. foam body made of polyester according to at least one of claims 1 or 2, characterized in that are contained as thermoplastic elastomers in the polyester foam thermoplastic copolyester elastomers.
4. Schaumkörper aus Polyestem nach Anspruch 3, dadurch gekennzeichnet, dass die thermoplastischen Copolyesterelastomere in Mengen von 0,5 bis 15 Gew.-%, bezogen auf das Gewicht des Schaumkörpers, enthalten sind.4. Foam body of polyester according to claim 3, characterized in that the thermoplastic copolyester elastomers in amounts of 0.5 to 15 wt .-%, based on the weight of the foam body, are included.
5. Schaumkörper aus Polyestem nach wenigstens einem der Ansprüche 3 oder 4, dadurch gekennzeichnet, dass die thermoplastischen Copolyesterelastomere Polyesterblöcke enthalten, wobei die Polyesterblöcke aus einem Diol, vorzugsweise aus 1 ,4-Butandiol oder 1 ,2-Ethandiol, und einer Dicarbonsäure, vorzugsweise aus Terephthalsäure, die mit PoIy- ethern, die Hydroxyl-Endgruppen tragen und in einer Kondensationsreaktion verestert werden, sind.5. A foamed body of polyester according to at least one of claims 3 or 4, characterized in that the thermoplastic copolyester elastomers contain polyester blocks, wherein the polyester blocks of a diol, preferably from 1, 4-butanediol or 1, 2-ethanediol, and a dicarboxylic acid, preferably from terephthalic acid carrying polyethers bearing hydroxyl end groups and esterified in a condensation reaction.
6. Schaumkörper aus Polyestem nach wenigstens einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, dass der Polyesterschaum eine Offenzelligkeit von kleiner als 8% und insbesondere von kleiner als 4% aufweist.6. foam body of polyester according to at least one of claims 1 to 5, characterized in that the polyester foam has an open-celledness of less than 8% and in particular less than 4%.
7. Schaumkörper aus Polyestem nach wenigstens einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass der Polyesterschaum eine Schubbruchdehnung von mehr als 12 %, zweckmässig von mehr als 16 % und bevorzugt von mehr als 50 % aufweist.7. A foam body made of polyester according to at least one of claims 1 to 6, characterized in that the polyester foam has a shear fracture elongation of more than 12%, usefully more than 16% and preferably more than 50%.
8. Verfahren zur Herstellung von Schaumkörpern aus thermoplastischen Polyestern, mit hoher Homogenität, niedriger Offenzelligkeit und hoher Schubbruchdehnung, enthaltend als Modifizierungsmittel Dianhydride von Tetracarbonsäuren,8. A process for the production of foams of thermoplastic polyesters, with high homogeneity, low open-cell content and high shear fracture strain, containing as modifier dianhydrides of tetracarboxylic acids,
dadurch gekennzeichnet, dasscharacterized in that
ein Polyester mit einer Vormischung aus thermoplastischen Elastomeren, vorzugsweise thermoplastischen Copolyesterelastomeren, und Dianhydriden von Tetracarbonsäuren versetzt, vermischt und zu einem Schaumkörper, enthaltend die thermoplastischen Elastomere oder thermoplastischen Copolyesterelastomere in Mengen von 0,5 bis 15 Gew.-%, bezogen auf das Gewicht des Schaumkörpers, aufgeschäumt wird.a polyester admixed with a premix of thermoplastic elastomers, preferably thermoplastic copolyester elastomers and dianhydrides of tetracarboxylic acids, and blended to form a foam body containing the thermoplastic elastomers or thermoplastic copolyester elastomers in amounts of from 0.5 to 15% by weight based on the weight of the polyester Foam body is foamed.
9. Verfahren zur Herstellung von Schaumkörpern aus Polyestern nach Anspruch 8, dadurch gekennzeichnet, dass der Polyester mit der Vormischung aus thermoplastischen Copolyesterelastomeren und Dianhydriden von Tetracarbonsäuren als Komponenten einem Reaktor oder Mischer, insbesondere einem Ein- oder Doppelschneckenextruder oder einem Mehrwellenextruder oder einer Tandemanlage aus zwei miteinander kombinierten Einschneckenextrudern oder aus einem Doppel- und einem Einschneckenextruder, zugeführt und darin vermischt werden9. A process for the production of foam bodies from polyesters according to claim 8, characterized in that the polyester with the premix of thermoplastic copolyester elastomers and dianhydrides of tetracarboxylic acids as components of a reactor or mixer, in particular a single- or twin-screw extruder or a multi-screw extruder or a tandem of two single-screw extruders combined or from a twin and a single-screw extruder, fed and mixed therein
10. Mittel zur Erzeugung von Schaumkörpern aus Polyestern, mit hoher Homogenität, niedriger Offenzelligkeit und hoher Schubbruchdehnung, enthal- tend als Modifizierungsmittel Dianhydride von Tetracarbonsäuren, dadurch gekennzeichnet, dass das Mittel eine Vormischung, enthaltend thermoplastische Elastomere, vorzugsweise thermoplastische Copolyesterelasto- mere, in Mengen von 25 bis 95 Gew.-%, bezogen auf das Gewicht des Mittels, und Dianhydride von Tetracarbonsäuren in Mengen von 5 bis 30 Gew.-%, bezogen auf das Gewicht des Mittels, darstellt.10. means for producing foam bodies from polyesters, with high homogeneity, low open-cell content and high shear fracture elongation, including as modifier dianhydrides of tetracarboxylic acids, characterized in that the agent comprises a premix containing thermoplastic elastomers, preferably thermoplastic copolyester elastomers, in amounts of from 25 to 95% by weight, based on the weight of the composition, and dianhydrides of tetracarboxylic acids in quantities from 5 to 30% by weight, based on the weight of the composition.
11. Mittel zur Erzeugung von Schaumkörper aus Polyestern gemäss Anspruch 10, dadurch gekennzeichnet, dass das Mittel eine Vormischung darstellt, enthaltend thermoplastische Copolyesterelastomere in Mengen von 50 bis 90 Gew.-%, zweckmässig von 80 bis 90 Gew.-%, und Dianhydride von Tetracarbonsäuren in Mengen von 10 bis 25 Gew-%, zweckmässig von 10 bis 15 Gew.-%, bezogen auf das Gewicht des Mittels11. A composition for producing foam bodies from polyesters according to claim 10, characterized in that the agent is a premix comprising thermoplastic copolyester elastomers in amounts of 50 to 90 wt .-%, suitably from 80 to 90 wt .-%, and dianhydrides of Tetracarboxylic acids in amounts of 10 to 25% by weight, suitably from 10 to 15 wt .-%, based on the weight of the composition
12. Mittel zur Erzeugung von Schaumkörper aus Polyestern gemäss wenigstens einem der Ansprüche 10 oder 11 , dadurch gekennzeichnet, dass das Mittel eine Vormischung darstellt, enthaltend 0 bis 70%, vorzugsweise 1 bis 50 Gew.-%, jeweils bezogen auf das Gewicht des Mittels, Stabilisatoren, Nukleierungsmittel, Flammschutzmittel und/oder Polyester, zweckmässig ein Polyester der gleichen Qualität, wie ein zu modifizierender Ausgangspolyester. 12. A composition for producing foamed polyester body according to at least one of claims 10 or 11, characterized in that the agent is a masterbatch containing 0 to 70%, preferably 1 to 50 wt .-%, each based on the weight of the composition Stabilizers, nucleating agents, flame retardants and / or polyesters, suitably a polyester of the same quality as a starting polyester to be modified.
PCT/EP2009/003911 2008-06-12 2009-06-02 Foamed polyesters and methods for their production WO2009149845A1 (en)

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